Blackbelt 3D look to change the paradigms of FDM 3D printing

BLACKBELT 3D large format printing

For prints of 1300mm or longer, Blackbelt recommend using the roller table to provide additional support during the printing process.

Blackbelt 3D first came to the attention of TCT Magazine via Twitter. The size and quality of the prints Blackbelt were sharing on the social media site caught the eye of an intrigued Dan O’Connor, TCT’s Group Editor.

A week later, Blackbelt have been in touch and have given us the first look at its industrial production machine, ‘designed to realise your ideas within a short time, and at low cost.’ Blackbelt wants to change paradigms in Fused Deposition Modelling (FDM) – They’re technology allows them to print extremely long parts, one after the other, with overhangs that don’t require additional support material. Unchartered territory for the industry so far, simply because nobody has developed the technology to overcome the hurdle. Until now.

Many components of the Blackbelt 3D are standard 3D architecture, according to the company. For example, the X-Y-actuation system hasn’t changed at all in the way it is structured, but has been slanted at a 45-degree angle. By printing at this 45-degree angle it is possible to print support-free overhangs on slanted geometry. To prevent the machine from printing on thin air, some parts require a starting geometry. The Blackbelt printer must start every new geometry on the conveyor belt, or onto a previous layer. Otherwise, material will be extruded into the air, and thus the part will ‘spaghetti’ rather than build. Blackbelt use the example of producing a plane model. Naturally, when laid flat on the build plate, the tip of the plane would be in the air. Therefore, a starting geometry must be added underneath the tip.

BLACKBELT 3D plane geometry

BLACKBELT 3D plane geometry 2

The red section represents the starting geometry which will enable the part to print without error. The diagonal lines represent the layers of the print.

Though Blackbelt say a 45-degree angle will work for most objects, it won’t work for all. Some geometries require a lower angle. For example, if it is necessary to print overhangs that tilt away from the machine, a lower angle can be used. The drawback here is that overhangs that incline toward the machine will print with a lower-quality surface.

Meanwhile, a high-precision conveyor belt becomes the new Z-axis and print platform, which moves horizontally with every new layer. Carefully selected, tried and tested carbon fibre composite has been used to make the conveyor belt, which allows the print to adhere and be positioned correctly. The conveyor belt also allows completed prints to be moved out of the way, so the next one can take place, making it ideal for volume production. A container can be attached to the front of the printer to collect the deposited parts.

BLACKBELT 3D container

The Blackbelt 3D printing part after part with the help of its conveyor belt and container.

The open build volume allows the user to produce prints of, theoretically, endless length. The gantry allows building products of 340mm x 340mm in x and y direction. For prints of 1300mm or longer, Blackbelt recommend using the roller table to provide additional support during the printing process.

What sounds like a complex system, is. Blackbelt believe the user must first be able to understand the design rules for parts, in order for them to be produced to the highest quality. But the Blackbelt team is ready to support its customers with their experience and CAD support, allowing everyone to get the most efficiency out of the platform.

BLACKBELT 3D print head

Print head with 0.4mm nozzle. The Blackbelt 3D printer also comes with a 0.6mm nozzle and 0.8mm nozzle.

The Blackbelt 3D printer is available as a desktop version and as a stand-alone machine. The stand-alone printer can be used with the optional downstream roller table, which allows longer products to be supported while the print takes place. Depending on print material, environment or printing geometry, the Blackbelt 3D printer can be modified individually to cater for the user’s needs and wants. Blackbelt has used BOSCH Alu profiles to construct the frame, making it easier to adapt the printer to any industrial or desktop environment. The printer also comes with three print heads, each possessing different nozzle diameters (0.4mm/ 0.6mm/ 0.8mm), that Blackbelt say are user friendly and safe to exchange.

Blackbelt 3D are set to launch a Kickstarter Campaign in the coming weeks, with the dates to be announced on Friday May 12th.